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Toyota temporarily idles pair of Indian plants due to labor unrest

The Detroit News reported today that Toyota will restart production at two Indian plants, following a shutdown on Monday.
Factory labor, management and police in Asia engage in the kind of violent altercations that we're not used to, having almost entirely walked away from the overtly brutal relations epitomized by the Pinkerton Detective Agency and the Flint Sit-Down Strike. In India, a plant owned by a Ford transmission supplier plant was shut down in 2009 after incidents between workers and armed men around the same time as Ssangyong workers occupied a factory in South Korea, in 2012 Suzuki Maruti workers rioted over wages around the same time upset employees beat a ceramics factory president to death in retaliation for a labor leader's killing.
Toyota is the latest to company trying to avoid that road. The Detroit Free Press reported earlier this week that it shut down two plants in India after 11 months of acrimonious wage negotiations and arbitration have gone nowhere. Toyota said the plant workers in Bidadi, near Bangalore, had deliberately stopped production at times over the past 45 days and threatened management. The workers said they wanted their wages raised by an amount already agreed to by management, but that management had reneged; news reports weren't clear on the amount, some saying nearly 10,000 rupees ($165 US) more per month, another saying 4,000 rupees ($65 US), but reports agree that Toyota has said it will only go as high as 3,050 rupees ($50 US).

Toyota retires robots in favor of humans to improve automaking process

Mitsuru Kawai is overseeing a return to the old ways at Toyota factories throughout Japan. Having spent 50 years at the Japanese automaker, Kawai remembers when manual skills were prized at the company and "experienced masters used to be called gods, and they could make anything." Company CEO Akio Toyoda personally chose Kawai to develop programs to teach workers metalcraft such as how to forge a crankshaft from scratch, and 100 workstations that formerly housed machines have been set aside for human training.
The idea is that when employees personally understand the fabrication of components, they will understand how to make better machines. Said Kawai, "To be the master of the machine, you have to have the knowledge and the skills to teach the machine." Lessons learned by the newly skilled workers have led to shorter production lines - in one case, 96percent shorter - improved parts production and less scrap.
Taking time to give workers the knowledge to solve problems instead of merely having them "feed parts into a machine and call somebody for help when it breaks down," Kawai's initiative is akin to that of Toyota's Operations Management Consulting Division, where new managers are given a length of time to finish a project but not given any help - they have to learn on their own. It's not a step back from Toyota's quest to build more than ten million cars a year; it's an effort to make sure that this time they don't sacrifice quality while making the effort. Said Kawai, "We need to become more solid and get back to basics."

Will Toyota lose up to 70% of its workforce in TX relocation?

Toyota's decision to move its US headquarters from its longtime home in Torrance, CA, to Plano, TX, was one of the biggest stories in the automotive industry this spring. With several months since the announcement, more details about the plan have leaked out. It seems that pulling up stakes could mean an even larger shakeup in the Toyota workforce than first thought.
According to Automotive News, Toyota intends to hang onto around 50 percent of its workforce in the move to the Lone Star State. However, even that figure might be optimistic. According to an unnamed insider speaking to AN, there is a fear the actual number could be closer to 30 percent. For comparison, Nissan retained about 42 percent of its workers in its move from California to Tennessee.
The actual percentage making the move is a mystery because Toyota is still rewriting its job descriptions under a single set of guidelines. The changes affect benefits, bonuses and the reporting structure, according to Automotive News, and employees' reactions could play a big role in who decides to go. According to an unnamed worker speaking to AN, the wait is hurting morale. Some people are even applying at the nearby Honda headquarters.